Electric resistance welding machine



Nov. 7, 1939.

H. A. DELAN ELECTRIC RESISTANCE WELDIILCLMAUHINE Filed Aug. 22, 1936 3 Sheets-Sheet 1 wm www E0.

O hm o .H. A. DELANO ELECTRIC RESISTANCE WELDING MACHINE Nov. 7

:s shets-sheet 2 Filed Aug. 22, 1936 INVENTOR e .fzvvo mgm! ORN Y Nw. 7, 1939. H. A. DELANO ELECTRIC RESISTANCE WELDING MACHINE Filed Aug. 22. 1936 5 Sheets-Sheet 3 is 4. wm,

MW ATTORNEY INVENTO YE HOW/7e Patented Nov. 7, 1939* PATENT OFFICE 2,179,117 ELECTRIC RESISTANCE WELDING MACHINE Howard York County, Pa.,

& Cable Company, York A. Delano, Springettsbury Township,` assignor to American Chain Inc., a corporation of New 4Application August 22, 1936, Serial No. 97,335

32 Claims.

The present invention has for an object to provide improvements in electric welding machines of the type in which two members are welded together by passing a heavy current through their` junction point and simultaneously pressing them together as they grow plastic under the heat'of said current.

The invention is particularly applicable to the Welding` of links of a formed chain, but, in its broader aspects, is not limited to such application.

An object of the invention is to provide improved means for controlling the application of the Welding current, wherein the inherent characteristics and properties of the Work, as well as the conguration of the vsame at the welding point, will vautomatically determine the duration of application of the current.

Another object of the invention is to provide for varying the pressure on the link, using a high pressure to compress the link while it is cold and automatically reducing the pressure to continue the compression as the link softens and becomes plastic.

Another object of the invention is 'to provide means for adjusting such pressures in accordanelli. with the nature and characteristics of the wor AnotherV object is to provide means for bringing the electrodes to bear' on the work in timed relationA to the application, of pressure thereon, the electrodes being' arranged to grip the work tightly and to follow the same as it is being compressed, thereby avoiding any noni-uniformity of electrical contact which might result from slippage between the work and the electrodes.

Another object of the invention is to provide a welding machine in which. the compression of 'the work is effected by straight line pressure -without the interposition of lever motions, of!- set tools, etc. A lmore specific object ofthe invention is to provide hydraulic means for compressing the work, such means being supplied by a pump with `adjustable pressure control means which may be calibrated in direct pounds of maximum pressure` on the work, so that the operator may conveniently-adjust the pressure according to the quality and size of the material which is to be welded.

- Other objects and advantages of my invention will appear in the following description of a preferred embodiment thereof, and thereafter the novelty and scope of the invention will be pointed' out in the claims.

In the accompanying drawings;

lThe shaft 3l in turn (Cl. 21S-5) Figure 1 is a plan view of the welding machine;

Fig. 2 is a view in longitudinal section taken substantially on the line 2-2 of Fig. i;

Fig, 3 is an enlarged view in section taken on the line 3 3 of Fig. l;

Fig. 4 is a View in transverse section taken on the line fl-Jl of Fig. 3;

Fig. 5 is a view in side elevation and partly in. section of the hydraulic shoving means as viewed from the rear, i. e., looking in the direction of the arrow e of Fig. il;

Fig. 6 is a view in transverse section taken on the line -t of Fig. 3; i

Fig. '1 is a view in side elevation of an electrical control device and a diagram of electrical circuits controlled thereby; and,

Fig. 8 is a diagram of the hydraulic supply system.

In the drawings the bed plate of the machine is indicated at Ill. Suitably mounted on this bed plate is a driving pulley Ii of reduction gears I2 and a clutch I3 drives a main shaft l that is suitably mounted in brackets supported on the bed plate I0. The shaft I4 runs adjacent the rear edge of the bed plate and immediately in front of this shaft is another shaft I5 paralleling the same and intermittently driven a quarter turn by the main shaft through a Geneva drive indicated generally at I6. A pair of miter gears I1 transmit motion from the shaft I5 to .an indexing shaft I8 which extends forwardly and carries at its forwardend a sprocket wheel (Fig. 2).

The wheel 20 is adapted to position the links at the welding point. A chain of formed links to be welded passes about a pair of guide pulleys 22 and 23 and then over the indexing wheel 20. Thence the chain passes do'wn under a vertically adjustable pulley 24 back over a vertically adjustable pulley 25 and through a trimmer 26 mounted on the underside of the bed plate, to another indexing sprocket wheel mounted on a shaft 21. The shaft 21 is driven by a chain belt 2B. The latter passes through a slot 29 in the bed plate and is driven by a sprocket wheel xed to a shaft 3l supported in brackets 3'2 `mounted on the upper face of the bed plate.

is driven by the intermittently operated shaft I5 through a pair of spiral gears 3l. The indexing wheel on shaft 21 serves to index the links in proper position with .respect ,to the trimmer 26.

which through a set It will be understood that the chain of links at the welding point are welded. After such alternate links have been welded the chain is passed through the machine again with the links which were formerly in horizontal position at 5 the welding point now turned over to vertical welding position.

At the welding point the link to be welded is engaged at opposite ends between a pair of opposed push rods, one of which is moved into operative position mechanically while the other is actuated by hydraulic means. The push rod 38 which is moved by mechanical means, is shown at the right hand side of Figs. 1 and 2, and is mounted to slide lengthwise in a pair of brackets 39-39 mounted on the bed plate. At its outer end said push rod is adjustably secured to a carriage 48 mounted to slide on ways 4| xed to the bed plate. The carriage is moved back and forth by a cam 42 lfixed to a shaft 43. 'I'he latter is mounted in brackets 44 and is driven from the main shaft |4'through a pair of helical gears .45. The cam 42 is adapted to advance the push rod byvengagement with roller 46 journalledin the carriage 48 and to retract the push rod by engagement with a roller 41 carried by an extension 48 of the carriage 40,

The hydraulically driven push rod 58 is adapted to slide in a bracket 5| xed to the bed plate and also passes through a carriage 52 mounted to slide in suitable ways 58 on the bed plate, as best shown in Fig. 3. The push rod 58 near its outer end (that is the end remote from the welding point) has a cross-head 54 fixed thereto. A cylinder'block 55 is fixed to the bed plate and has a main bore 56 within which four telescoping sleeve pistons 51, 58, 5.8 and 68 are ttedto slide. The innermost piston 68 is fixed to the outer end of the shaft 58 and bears against the cross-head 54. The other pistons are arranged to bear also against cross-head 54 when it is desired to exert a maximum hydraulic pressure on the push rod.

Means are provided for selectively cutting oil one or more of said other sleeve pistons so as to-variably reduce the pressure exerted on the push rod 58. This selective means comprises a finger 5| which is carried by a threaded stem 52, the latter being adjustably clamped to a xed bracket 58 between a pair of nuts 54 and 55.

The outside sleeve piston 51 is of such diameter that it will always engage the hub of the linger 5|, but the others will clear said hub. As shown in Figs.' 5 and 6 the sleeve piston 51 is outback or recessed at 55 to clear a lug 88 projecting y the next inner sleeve piston 58.

The latter sleeve piston is also cut back or recessed at 59 to clear a lug 18 projecting from the next inner sleeve piston '58. 'I'he linger 5|, as explained above, normally will stop the outside piston 51 when the latter has been advanced to the position shown in Figs. 3 and 5. If the nger is swung to the position shown in Fig. 4

it will also engage the lug 58 to stop the sleeve piston 58 but will clear the lug 1.8. The nger may be swung upward from the position shown in Fig. 4 to engage also the lug 18, if so desired, so

as to stop the sleeve piston v59. This would leave only the innermost sleeve-piston 58 acting to ad- Y Vance the push rod 58. In order to brace the I0 finger 5| when it is engaging one or both of the lugs I provide a set screw 12 threaded into the bracket 53 and be against the nger, as shown clearly in Fig. 5. A jam nut 18 holds the set screw in adjusted position.

' 75 Fixed uponfthe shaft sa isa cenar u which plays between a pair of adjustable sleeves 15 and 15 which are threaded into vertical extensions of the carriage 52, as shown in Fig. 3. The sleeve 15 is preferably so =adjusted as to contact the collar 14 when the sleeve piston 51 encounters the stop nger 5| so that further movement of the push rod 58 due to a hydraulic pressure on piston 58 and such other pistons as are not engaged by the stop linger will cause the carriage 52'to advance with the push rod.

The push rods themselves donot actually contact with the link to be welded but are provided with thrust pins which are electrically insulated from the rods. This construction is shown in Fig. 5. It will be seen that the push rod 58 is formed with a head 18 in which there is a socket lined with insulating material, as indicated at 80. Fitted within this lining is a plug 8| formed with a tapered socket to receive a thrust pin 82 which makes the actual contact with the link to be welded. A transverse slot 83 extending through the head and plug permits oiintroducing a wedge to force the pin 82 out of its socket whenever so desired. By this arrangementv it will be evident that the pin is insulated from the push rod. A similar construction is provided for the'pin 83 of the opposite push rod 88.

'I'he cross-head 54 of the push rod 58 is connected by tie rods 85 to a cross-head 85 at the opposite end of the block 55 and, as shown in Fig. 5, piston rods 81 are secured at one end to the cross-head 85, while their opposite endsenter bores 88 formed in the cylinder block 55. Each rod 81 is provided with a cupwasher or piston 89.

Hydraulic iiuid under pressure is introduced into the bores 88 through Atubing 98, so that there will be a constant pressure on the pistons 89 tending to return the rod 55 to its Anormal retracted position. When the push rodis to be advanced into engagement with a link, oil or other hydraulic fluid under pressure is admitted through a pipe line 82 into the cylinder bore 55 causing the pistons 51, 58, 58 and 58 to move outwardly or toward the right, as viewed in Fig. 3, overcoming 'the pressure bores 88.

Admission of operating fluid to the cylinder 55 and discharge oi' fluidtherefrom is controlled by a cam 85 xed to the shaft I4, and operating a valve 85, as will be explained more fully hereinafter. When the iluid incylinder 55 is connected to discharge the rod 5I returns to normal position by action of the iluid pressing upon the pistons 88, and the collar 14 upon engaging the sleeve 15 returns the carriage 52 to normal position. It will be observed that there is considerable lost motion of the collar 14 between sleeves exerted by the uid in the cylinder 15 and 15, so that the actual advan and return o of the carriage 52 is comparatively slight.

Welding current is supplied by two pairs of electrodes, to the link positioned at the welding point by the indexing sprocket 28, one pair |88 being disposed on one side ofthe joint to be welded and the other pair 8| on the other side. The electrodes |88 are carried by a pair of opposed levers |82 which are operable to move the electrodes into and out of contact with the link. The levels are pivoted intermediate their ends on a vertical -pin |84. The pin is supported at the top and bottom in a yoke bracket |85 fixed to the baseplat'e I8. and is transversely aperured to permit the push rod 38 to slide therethrough. By spreading the outer ends (the right hand ends as viewed in Fig. 1) ofthe levers |82 The arms thereto and between which is located a hydraulic to the cylinder .and

apart, the electrodes are moved into rm contacting engagement with the link to be welded.

The levers are operated by a pair of opposed drum cams |06, which are xed on the shaft 43, so that the contacting of the electrodes with the link bears a definite time relation to the thrust of the push rod 38. However, the cams do not act directly on the levers |02 but exert a resilient pressure thereon so as to allow for variations in link stock. To this end a bell crank is pivoted on the outer end of each of the levers |02. One arm |08 of this bell crank engages a cam slot in the adjacent drum cam |06, while a spring ||0 is interposed between the other arm |09 of the bell crank and the adjacent lever |02. Thus, as the cams spread the arms |09 apart, the electrodes |00 will be brought into engagement with the work and the springs I I0 will yield to prevent the imposition of more than a predetermined pressure of the electrodes on the work.

The electrodes |00 open only suiiciently to clear the link as it is being brought into and is being withdrawn from welding position, and they close upon the link substantially simultaneously with the forward movement of the push rod 36, because the latter is not intended to move the link but merely to provide an abutment'therefor. Consequently, movement of the electrodes |00 in the direction of 30 the axis of the push rod 38. The electrodes |01,

however, are adapted to move with the push rod 59 during the actual welding operation so that as the link is compressed endwise to form the weld there will be no slippage between the electrodes |0 35 and thev link which might 'disturb the electrical Icontact therewith. The electrodes |0| are car-v ried by two opposed levers ||2 which are pivoted on a, pin ||3 through which passes the push rod 50. The pin l|3 is' supported at the top and Abottom in the carriage 52, so that as the carriage is moved forward by pressure of collar 14 upon sleeve 16, it will carry the electrodes forward with it. The levers ||2 have'arms ||4 which extend outwardly or away from the welding point and which are normally urged toward each other by means of a spring ||6, thereby tending to spread the electrodes apart so as to clear the link. However, the electrodes are forced into engagement with the link by hydraulic means as willnowbe explained.

||4 have slotted extensions ||8 fixed cylinder ||9-. Slidable in and projecting in opposite directions from this cylinder are two pistons |20 which are connected respectively to the arms ||8.`-The cylinder ||9 is mounted on a carriage |22 (Fig. 2) which is arranged to run on tracks '|23 supported by `a bracket |24 secured to the adjacent end of the base plate I0. Hy-

' draulic fluid under pressure is admitted to the cylinder ||9 between the pistonsI to force them apart and thereby force. the electrodes |0| into good electrical contact with the link at the welding point. The operating fluid is led to and from the cylinder |09 through a pipe line |29 under control of a valve |30 which is operated by a cam |3| on the shaft |4 to alternately admit pressure release pressure therefrom. The carriage |22 permits the cylinder ||9 and pistons |20 to be moved to different positions alongy the extensions 1| I8 so as to vary the leverage thereon. To this end, a series of pin holes |33 is'provided inA each extension ||8 through which pins |34 may beinserted to secure the pistons |20 at the desired adjustment.

it is not necessary to provide for any r vare also provided on the 'I'he electrodes |00 and l0| are connected to exible laminated leads |35 which pass through openings in the base plate |0 and are connected under the base plate to suitable bus bars |36.

Means are provided for automatically controlling the duration of application of the welding current in accordance with the cross-sectional area, and inherent characteristics of the link stock, as will now be explained. Fixed upon the bed plate I0 adjacent the carriage 52 is a bracket |39. Pivoted on this bracket at |40, as shown more clearly in Figure 7, is a bell crank lever comprising a vertical arm |4| and a horizontal .arm |42. A spring |43 tends t0 draw the arm |42 downwardly so that its outer end normally rests upon a shoulder or step |44 formed on a postv |45 carried by the bracket. Mounted on the ,upper edge of the arm |42 but insulated therefrom is a spring contact |46. A contact screw |41 overlies the Contact |46. This screw is adjustable in a block |48 carried by but insulated from the post |45.

A solenoid i() is mounted on the vertical arm |49. The movable core of this solenoid has a downwardly projecting stem |52 which passes through a sleeve |53 secured to arm 14|. A'rod |54 is pivotally connected at one end to the carriage 52 and its opposite end projects through an aperture in the sleeve |53 and through a slot |55 formed in the stem |52. The arrangement is such that when the solenoid is energized the stem |52 will be drawn upwardly and will thereby clutch the rod |54- so that upon movement of the carriage 52 the bell crank lever |4||42 will be rocked on its pivot |40. Thus, after the carriage 52 has moved forward a predetermined distance the spring |46 will make contact with the screw |41, closing an electric circuit which, as will now be explained will operate to open the primary circuit of a transformer which supplies the welding current.

The primary winding of the transformer is indicated at |51 and the secondary at |58. The primary winding is supplied with current through line wires |59 and |60. The wire |59 may be connected at any one of various predetermined points to the winding |51. A number of taps |6| primary winding and are adapted to be engaged by a switch arm |62 connected to line |60, less of the primary winding. A circuit breaker |64 is provided in the line |60. This circuit breaker is normally open, but is adapted to be closed by a solenoid |65 in a shunt line |66 across lines |59 and |60. The shunt line includes a switch |68 which is normallyclosed and which is controlled by a solenoid |69. The latter is adapted` to be energized by a battery |10 when the spring |46 makes contact with the screw |41. To this end a line |1| which includes the solenoid |69, is connected at one end to one pole of the battery and at the other to the spring |46, while the other pole of the'battery |10 is connected by a line |13 to the contact screw |41. Thus, when the circuit through the solenoid |69- is energized by the rocking of the bell crank |4||42 and the conse-'- so as to cut out more or |16 bridging lines |13 and |1|. `A double pole switch |11 which is normally held open by a spring |18 lis arranged to close a. gap inthe line y |66 and also in the line |16. Thus, when this 4 aivanv line is cut-E and the line 92 connects with the switch is closed the solenoid |65 will be energized to close the circuit breaker and supply energizing current to the primary winding |51 of the transformer, and at the same time the soles noid |50 will be energized to clutch the bell crank |4|-|42 to the carriage 52. The double pole switch |11 may be operated automatically by a cam on the shaft |4 or this cam may be removed and the switch be operated manually.

10 The control provided by the mechanism just described is such that when theswitch |11 is closed, such closure occurring when the push rod 50 has substantially closed the joint in the link to be Welded, the welding current is automatically 1.-, 4turned on and will continue tube applied as the link is rendered plastic by the heat of the weld- 'ing current and`is gradually compressed by action of the hydraulic piston or pistons in the cylinder 56. When the carriage 52 has advanced to a predetermined degree the spring |46 will Contact with screw |41, thereby energizing solenoid |69 and opening switch |68. This will deenergize solenoid |65 causing the circuit breaker to open and stop the flow of energizing current to the primary |51 of the transformer.

After the weld has been formed it is swedged in the usual manner by-a pair of hammer levers |00, Fig. 2, which are pivoted on a transverse shaft mounted in brackets |82. A cam |84 is :m mounted in vertical extensions of the brackets |02 and is driven through a pair of helical gears by a shaft |86 (Fig. 1) which, in turn, is driven through a pair ofhelical gears |81 by the shaft I4. The cam |84 is formed in opposite :i5 faces thereof with grooves which are engaged by the hammer levers |80, so thatl the hammers are thereby operated at the proper period of time.

The trimmer 26 is operated in the usual man- 40 ner to shear oi the burr left on the link after the hammers have operated'thereon. This trimmer is controlled by'a cam |90 mounted on shaft |4 and operating a bell crank lever |9| which projects through an opening in the bed plate I0 4,-, and is suitably connected to the usual shearing knives in the trimmer 26.

The hydraulic pressure system is illustrated, somewhat diagrammaticallyvin Figure 8. Oil or other hydraulic operating fluid is pumped from m a reservoir |95 by a motor driven rotary pump |00 and forced into a pressure chamber |01. In order to maintain a substantially constant pressure in thischamber a by-pass is'provided connecting the pressure chamber to the suction chamber |00 of the pumpand this by-pass is controlled by a valve 00. The valve is urged to closed position by a spring 200, the pressure of which may be adjusted by means of the adjusting screw 20|. 'I'he strength of the spring 200 su thus determines the dilerence in pressure between the pressure and suction chambers. A gage 202 is provided to 'determine the pressure in lthe chamber |01. Leading out of the chamber |01 is a delivery line 200 which is in constantc.; communication with the tubing leading to the cylinder 08. A branch 204 leads from the delivery line to the three-way valve .00 and another branch 200 leads tothe three-way valve |00. 'Ihe valve 00 is connected by pipe line 02 to the cylinu der 00 and by-discharge line 206 to the suction chamber |08 ol' the pump. Similarly, the valve |00 iseonnected by the pipe line |29V to the cylin- -der ||0 and by discharge line 201 to the suction chamber |08. Normally, the valve 96 is urged by a I '.'5 spring 208 to a position in which the delivery line 206. Similarly, a spring 209 normally holds the valve |30 in such position as to connect lines |20 and 201 and to disconnect line |29 from the delivery line 205. When the cam operates the valve 06 against the pressure of spring 200, the discharge line 206 is cut off and oil under pressure is then admitted to the cylinder 58 forcing the pistons therein outwardly against the opposing pressure of the pistons 89 in the cylinders 00. Similarly, the cam |3| operates to connect cylinder ||9 to pressure and to disconnect it from the discharge line 201. The gage v 202 is preferably calibrated to. indicate in pounds the maximum pressure vof the set of pistons in the cylinder 56 on the link that is to be welded.

Hence, whenever there is a change in size or quality of the work which would require a different pressure the set screw 20| may be adjusted to increase or reduce the pressure of the spring 200 until the requisite hydraulic pressure is indicated on the gage 202;

Operation of the machina- The clutch I3 is of the type which will stop automatically at the end of each complete turn and also at a predetermined intermediate point.' A manually operable clutch lever 2|0 is provided to re-engage the clutch after each stop. A cycle of operations starts after a weld has been completed and the electrodes |00 and |0| have been withdrawn, but with the welded link still held between the push rods 38 and 50.

'I'he first operation, after the clutch has been engaged, is for the cam 42 to start withdrawing the push rod 38 and the cam 95 to release the valve 96 so that the cylinder 56 will discharge its operating fluid and the pistons 89 will retract the push rod 50. After the push rods have been completely withdrawn the Geneva motion I6 causes shaft |5 to make a quarter turn, so that the indexing sprocket 20 will withdraw the welded link from welding position and bring the next vertically disposed link into welding position. A't the same time, the indexing shaft 21 will be operated to feed the chain through the trimmer 26 so as to bring the next welded link into proper position for trimming. As soon as the links have thus been properly indexed, the cam 42 operates to force the push rod '38 forward to operative position and at the same time the cams |06 operate to for the electrodes |00 into clamping engagement with the new link at the welding point. Immediately after the push rod`80 has started forward the valve 96 is again operated by a cam 05 to admit oil under pressure to cylinder 56. 'Ihis causes the entire set of telescoping pistons in the cylinder to advance against the crosshead 54 and thereby force the push rod 50 against the link. 'I'he combined pressure of the pistons is suilicient to'close the gap in the joint to be welded, the linger 0| being arranged to arrest one or more of the pistons as soon as this has.

been effected. While the push rod 50 is being advanced pressure is admitted tothe cylinder I0 by action o f cam |3| on valve |30 so that the'electrodes |0| close upon the link with a pressure determined by the hydraulic pressure in the cylinderV ||0 and the leverage provided by adjustment of the pistons |20 along the extension arms I0. The parts are so adjusted that at the time when the gap in the link is closed the collar 14 will engage the adjustable sleeve 16 and will force the carriage 52 forward with the forward motion of the push rod 50. At the same time, the cam |10 will operate to close the switch |11, thereby 10 push rod 50. -As the link softens under the influence of the heat supplied by the welding current it will yield to this pressure and the push rod 5,0 together with the carriage 52 supporting the electrodes will slightly advance. Since 'the bell crank lever |4I|42 is clutched to the carriage 52, forward movement of this carriage will tilt the bell crank on its axis |40 until contact is made between spring. |46 and |41. This, as' explained above, will energize solenoid |69, thereby open- 20 ing switch |68 and deenergizing solenoid |65, so

that the circuit breaker will open under influence of spring |15 and stop the flow of welding current. As the weld cools the advance of push rod.

50 is arrested.

After the weld has been allowed to cool to a sufficient extent the operator re-engages clutch I3 and immediately thereafter cam |19 clears the switch |11 and spring |18 opens the same. The solenoid |50 is thus deenergized and the bell crank lever |4||42 is declutched from the carriage 52,.` Thereafter, the electrodes are withdrawn by operation of cams |06 acting on the electrode levers therewiththe cam |3| releases valve |30 so that 35 the fluid will discharge from cylinder H9, permitting the spring ||6 to withdraw the electrode |0I from the work. While this is taking place the hammers |80 swedge the weld in the usual manner and the trimmer 26 operates to cut off the fins on the link which is in operative position in the trimmer. The push rods 38 and 50 continue to occupy their advanced position, however, and the clutch |3 now disengages a second time completinga cycle of operations.

It will be observed that the duration of application of welding current depends upon the condition of the work and is not controlled by a set time period. The work has to soften sufciently for the parts to be moved a certain distance before ige welding current is cut off and this distance m y be varied for different classes of work by suit le adjustment of the' set screw |41. If desired, the application of the welding current may be effected by manual operation of the switch I 11 as'soon as the clutch disengages the rst time and the operator has to hold this switch in closed position until the circuit breaker is automatically opened. Actually, the switch |11, whether operated automatically or manually, is not .closed until after the gap at the joint ingthe linkV has been closed, no matter how wide such gap may originally have been. Sincethe push rod is movednon-positively, that is, by hydraulic means which cannot exert more than a predetermined pressure, the push rod 50 merely stalls afterclosing the gap and then resumes its movement after the link has been softened by the welding current. Thereafter, the duration of application of the welding current depends upon a predetermined measure of travel of the push rod, starting from the point of actual contact of the opposed link elements at the joint. Thus, de-

spite irregularities in a chain of formed links,l

such as a wide variation of spacing at the joints,

or a variation of cross-section or of structural |02, andv simultaneously characteristics of the opposed elements at the joints, there will be a uniform compression of the links during the actual weld for any given setting of the machine, andthe application o'f the weldingl current will be measured, not in time, but

in distance travelled by the push rod 50, or, in other words, by the endwise contraction of the link after contact has been established between the opposed link elements.

The provision of a number of telescoping pistons acting on the push rod 50 permits of adjusting the pressure as desired during the welding operation. Full pressure is provided to close the gap in the link but thereafter the pressure is reduced in accordance with the nature of the work so as to prevent an excess of pressure which might distort the link while the weld is being made. This 'reduction of vpressure during the shove is controlled by theiinger 6| which may cut oi` one or more of the pistons while the maximum pressure is controlled by adjusting the spring pressure on the by-pass valve |99 in the pump.

An important feature of my invention consists in the mechanism whereby the electrodes whenthey engage the work do not slip with respect to the work but by reason of engagement of collar 14 with the adjustable sleeve 16 on the carriage 52 the electrodes |0l travel forward with the push rod 50 and hence with the link as it is being compressed, thereby insuring a perfect electrical contact during the welding operation.

The machine may readily be adjusted to take care of larger or smaller links. To this end,- the point at which the outside piston or pistons op-- erating on push rod 50 are cut oil", may be adjusted by Varying the position of finger 6| Vwith respect to bracket 63. Also, the lost motion between adjustable sleeves 15 and 16 may be regulated and the sleeve 16 may be adjusted to start the forward movement of the carriage 52 at the desired point in the travel of the push rod 50. The pressure of the electrodes |00 upon the work is also adjustable for various sizes of work and because of the resilientoperative connection with cams |06, while the pressure of electrodes I0| may be regulated byvarying the,

points of engagement of pistons |20 with extension arms H8.

` It is common practice in various resistance Welders to employ means which functions to interrupt the welding current as a squeezing jaw reaches a'ny preselected position of its travel. If such means were employed in chain link welding machines, links formed slightly short would be underheated and links formed slightly long would be overheated and the lengths of the welded links would-be the same butl the welded joints would not be of the same strength and would not be uniformly strong. By using the means disclosed in this application, whether the links are long or short, the welding current is left on until the amount of compression ofthe weld amounts to a predetermined figure at which time the Welding current is turned off. The welded joints will be uniformly strong. Obviously unwelded links initially long and unwelded links initially short, will, after welding, be respectively long and short and `not of uniform length but this is not objectionable. l

This machine completely controls the length of welding time based on the ability of the materialto withstand pressure which is fundamentally connected with the temperature of the material in the welded zone.

Ihe particular type of cut-od disclosed measures the temperature by the plasticity of the metal heated, a measurement which for a given alloy is just as accurate as measurement of temperature, and more accurate by far than any measurement of time.

The cut-ofi' of the current at a predetermined time is controlled by an adjustment and is effective without reference to the position of the 10 thrust member relative to a fx'ed part of the machine. In other words, if the link to be welded should be long or short it would not aifect the adjustment, as the measurement is only taken after the two lengths or the ends of the links have been moved firmly together under pressure.

This machine includes means for moving the electrodes exactly with the collapse of the link, thus in no way changing the contact. area or the current flow into the link during the'welding operation.

One important feature of this invention is the provision of means for effecting a heavy pushup during the rst part of the link welding operation and a light push-up during a succeeding part. A variableV pressure effect is provided by the use of several pistons which are automatically cut in and out of the pressure cycle in such a way that a maximum pressure can be exerted during the first stage of the welding operation,

and then the pressure can be eut down to a definite pre-determined value as soon as the link has become suiciently heated and softened to make its resistance to the higher pressures impractical. 'Ihe thrust member exerts its full pressure against the cold link, and after a predetermined shcve has been effected, which will be of sufficient amount to clean the welded zone of foreign material in the form of a flash, the main piston and oneor more auxiliary pistons 40 are actually stopped and the remaining pistons of predetermined sizes continue the shove, upsetting and holding the welded section rm during the actual welding operation and cooling period.

It is desirable to exert a high pressure during the warming period and reduce this pressure as the welding areas approach the plastic state. Without this higher pressure at the start abutting surfaces below the average tend to develop abnormally high resistance resulting in fusing of the metal and showering it out in all directions.

By means of the several pistons telescoping in one cylinder, a variable pressure can be applied during the operation. This arrangement is so made that all but one of the pistons can be used through the entire stroke of the welder, or one lor more pistons can be stopped at any pre-determined point in the welding cycle, thus allowing the other pistons to carry through and maintain the required amount of pressure for nishmg the welding. This has vbeen found almost necessary in. the softer alloy materials. 'Ihe spring backin a link has to be continually overcome until the weld is of to withstand the load.

Apparently different maten'als have different compressive strengths when raised to high temperatures, and this fundamental phenomena of the link material is dealt with by changing the rect reduced pressures.

On some materials the heated zone at the weld is much shorter than on material where the electric conductivity is high. In this case, a much 75' smalleramount of material is heated and, theresuilicient temperatureA angular position of the stop to furnish the corfore, the pressure required to distort this material is considerably more than on bronzes and material of this nature. It is found necessary therefore on the higher tensile stiffer materials, as stainless steel, to maintain a higher pressure during welding than on the bronzes.

It is always advisable to put as much pressure as possible on a link to be welded prior to reaching the softeningpoint of the material handled, to allow a larger flow of energy into the joint to cause a more rapid heating. If the pressure is low, a sufficient amount of power can not be put through the link to bring the temperature of the joint up to welding in a reasonable commercial time.

On bronzes and metals of high electric and heat conductivity, Where a larger area is heated at the welded zone, it is necessary to reduce the pressure as the weld progresses to some predetermined point.

In the operation of the Welder, the mechanical pusher comes up against the link immediately followed by the engagement of the associated electrodes with the sides of thelink. The hydraulic softens, the hydraulic pusher follows up with a.i

firm pressure until it reaches the point where one of the pistons is cut out by the stop. Thecurrent is taken off of the link at a suitable time with respect to the functioning of the stop. The current is cut olf by a device which functions entirely independently of the position of the pusher with respect to the bed of the machine and which operates when the amount of shove or compression of the weld'ed link has reached a denite value.

In welding stainless steel it has been found a' most satisfactory to start the operation on high pressure, to provide a good electrical contact between the ends of the link and to overcome the resistance to closing the link and the initial upsetting of the link, and then to reduce the pressure to a predetermined amount after an initial upsetting operation in which the fused material is forced out of the joint, and maintaining this reduced pressure constant throughoutthe final up- 5,

setting operation and during the cooling period. The initial high vpressure can be adjusted by the control means on the pump which also affects the reduced pressure, the relation of which to the initial pressure can be changed by disabling o` e or more of the pistons. In welding materials of .ower conductivity such` as steels, particularly alloy steels, the original pressure of closing the link is reduced at or slightly after the welding current has been interrupted. In welding forms of bronze the original pressure of closing the link is maintained up to a short time before the welding current is taken olf and then the pressure is reduced for the holding or cooling period which reduced pressure is maintained until the link is suiciently cooled to recycle the machine. The point in the travel of the take-up during the welding operation at which the pressure is Vreduced is controlled byl the longitudinal adjustment of the control finger 6I and the proportionate amount of reduction in pressure, by an angular adjustment of the control nger 6I to arrest one or more of the 'pistons after a desired amount of i upset has taken place. This point depends upon the characteristics of 'the material to be welded and is preferably chosen so that the initial high pressure forces the fused material out of the joint and forces the zones of the material which are at welding temperature into molecular locking en- 10 gagement. 1

While I have described a preferred embodiment of my invention it will be understood that this is to be taken as illustrative and not limitative and that I reserve the right to make various changes in design, construction, arrangement of parts and mode of`operation without departing from the spirit and scope of my invention as pointed out in the following claims- I claim:

'1. An electric resistance welding machine for Welding the joint of a chain link, said machine comprising an abutment member for one end of the link, means adapted to move the abutment member to a fixed Welding position, a thrust member, means adapted to advance said thrust member against the other end of the link to compress the link between the members, an electrode, means operable in timed relation to the movement of the abutment member to contact said electrode with the link on the side of the joint adjacent the abutment, a second ele'ctrode,

means operable in timed vrelation to the advance" of the thrust member to contact the second electrode with the link at the opposite side of said joint, means for applying a welding current to the electrodes after they have made contact with the link, and means adapted to advance said sec- -ond electrode with the thrust member,

2. An electric resistance welding machine for` Welding the joint of a 'chain link, said machine comprising an abutment for one end of the link, means adapted to move the abutment to a fixed Welding position, a thrust member, means adapted to move said member against the other end of the link to compress the link against the abutment, a pair of electrodes, means operable in timed relation to the movement of the abutment and the thrust member to contact the electrodes with the link at opposite sides of said joint, means for applying a welding current to the electrodes after they have made contact with the link, and means on the thrust member adapted to engage 'the electrode adjacent thereto at a predetermined point in the compression stroke of said member to advance the electrode' with the thrust member.

3. An electric resistance welding machine for weldingr the joint of a chain link. said machine comprising a pair of thrust members adapted to engage opposite ends of the link, aA hydraulic pressure means, at least one of the members being adapted to be advanced by said pressure means to compress the link, said pressure means comprising a plurality of hydraulically operated v pistons adapted to bear on the latter member, means "for applying a Welding current across said joint after said link has been closed, means for arresting one of the pistons upon a predeterminedtravel `of the same to reduce the compressive force on .the link during the welding operation, and means for'inter'rupting said welding current after a predetermined amount of travel of another of said pistons measured from the position said latter piston occupied when said joint was closed.

4. An electric resistance welding machine for welding the joint of a chain link, said machine comprising an abutment member and a thrust member adapted respectively to engage opposite ends of the link, hydraulic pressure means comprising'a' cylinder and a plurality of telescoplng pistons operable in the cylinder and adapted to advance the thrust member to compress the link between the two members, means for applying a welding current across said joint after said joint has "closed, a stop for arresting one of thepistons to reduce the pressure on the thrust member when the latter has been advanced by the pistons to a given point, and means for interrupting said welding current when said thrust member has been advanced a predetermined distance from the point it occupied when said joint was closed.

5. An electric resistance welding machine for welding the joint of a chain link, said machine comprising an abutment member and a thrust member adapted respectively to engage opposite ends of the link, hydraulic pressure means compistons operable'in the cylinder, said pistons be ing arranged to bear against the thrust member t to compress the link between the two members, and selective stop means settable'to arrest any or all of the pistons except one at a predetermined point in the pressure stroke of the thrust member so as to reduce the compressive force on the link. y

6. An electric resistance welding machine for Welding the joint of a chain link, said machine comprising an abutment member and a thrust member adapted respectively to engage opposite' ends of the link, hydraulic pressure means comprising a cylinder and a plurality of teles'coplng pistons operable in the cylinder, said pistons being arranged to bear against the thrust member to compress the link between the two members, and selective stop means settableto arrest any or all of the pistons except one at a predetermined point in the pressure stroke of the thrust member so as to reduce the compressive force on the link, said selective means being ad justable toward and from the welding point to vary the point at which the pistons are arrested.

7. An electric resistance welding machine for welding the joint of a chain link, said machine comprising an abutment member and a thrust member adapted respectively to engage opposite ends of the link, hydraulic pressure means comprising a cylinder anda plurality of telescoping pistons operable therein and adapted to advance the thrust member toward the abutment member 'comprising an abutment member and a thrust member adapted respectively to engage opposite ends of the link, hydraulic pressure means 'comprising a cylinder and a plurality of telescoplng pistons operable therein and adapted to advance,`

the thrust member toward the abutment member to compress the link therebetween, a stop adapted to arrest one or more of the pstpns to reduce the pressure on the thrust Amember when the latter has, been advanced to a predetermined point, means operating in timed relation to such prising a cylinder and a plurality of telescoping,A

reduction of pressure to pass a welding current through the joint, whereby the link will be softened by the welding current and willl continue to be compressed at reduced preure, and means for interrupting the welding current at a predetermined point in the travel of the thrust member under reduced pressure which point is measured from a point at which the joint in the link is closed.

9. In a machine for welding a joint of a chain link, an abutment member adapted to bear against one end ofthe link, a thrust member adapted to bear against the opposite end of the link, a main cylinder, a main piston operable therein and adapted to bear against the thrust member, a second cylinder of smaller diameter than the main cylinder, a retracting piston operable therein and connected to the thrust member, a` pump adapted to supply hydraulic operating iluid to the two cylinders, means adapted to maintain the delivery side of said pump in constant communication with said second cylinder on the forward sideY of the retractingpiston so as to exert a constant force tending to retract the thrust member, means for connecting the main cylinder to the delivery side of the pump on the rearward side of the main piston, so as to overpower the retracting piston and compress the link between the two members, a valve in the connecting means operable to cut oif the main cylinder from the delivery side of the pump and to connect the same to the intake side of the pump, and vice versa.

10. An electric resistance welding machine for welding together a pair of elements that are normally sprung apart, said machine including means for pressing the elements together in abutting relationship, means for passing a welding current through the junction point of the elements while they are pressed together, and means adapted automatically to reduce the pressure to a lower constant value after the elements have been abutted, so as to maintain a lower pressure on said elements while the welding current is applied.

1:1. Anelectric resistance welding machine for closing and welding the joint of a chain link, said machinel comprising a pair of opposed thrust members relatively movable to compress the link therebtw n in such direction as to close said joint, m ans for applying pressure ,to the thrustl members suillcient to close said joint while the link is cold, means for passing a welding current through said joint after the joint has been closed, and means adapted automatically to re.- duce said pressure to a lower constant value after a predetermined relative movement of the members.

12. An electric resistance welding machine for closing and welding the joint in a side of a chain link, said machine comprising a pair of opposed thrust members relatively movable to bear against opposite ends of the link, means for applying a pressure to the thrust members sumcient to compress the link and close said joint while the link is cold, means for passing a welding current through said joint after the joint has been closed,

and. means adapted automatically to reduce said pressure to a lower constant pressure after a predetermined relative movement oi' the members.

13. Anelectric resistance welding machine for closing and welding the joint in a side of a chain link, said machine comprising an abutment member adapted to bear against one end of the link,

a pair of electrodes, means for operating said electrodes to grip the link at the abutment side of the joint, a thrust member adapted toV bear against the opposite end of the link, means for advancing the thrust member against the link with suiicient pressure to close the joint, a second pair of electrodes, means operable in timed relation to the advance of the thrust member to cause said second pair of electrodes to grip the link at the thrust member side of the joint, means for passing a welding current from one pair of electrodes to the other through the joint after the electrodes have gripped the link, means for reducing the pressure on the thrust member whereby the thrustmember will assume its 'advanceat a lower pressure duringapplication of the welding current, and means adapted to advance the second pair of electrodes with the thrust Vmember while the welding current is applied.

14. An electric resistance welding machine for `closing and welding thev joint in a side of a chain link, said machine comprising an abutment 4member adapted to bear against one end of the link, a pair of electrodes, means for operating said electrodes to grip the link at the abutment side of the joint, a thrustl member adapted to bear against the opposite end of the link, means for advancing the thrust member against the link with suilicient pressure to close the joint, a second pair of electrodes, means operable in timed relation to the advance of the thrust member to cause said second pair of electrodes to grip the link at the thrust member side of thel joint, means for passing a welding current from' one pair of electrodes to the other through the joint after the electrodes have gripped the link, means adapted to advance the second pair of electrodes with the thrust member while the vwelding currentjs applied, and means for adjusting the gripping pressure of each pair of electrodes on the link.

15. An electric resistance welding machine for successively closing and welding the joints of a series of chain links of the same dimensions except ,for variations in manufacture, said machine comprising a pair of opposed thrust members relatively movable to compress the links therebetween in such direction as to close said joints, means for applying pressure to the thrust v`members suillcient to close said joints while the links are cold but insuillcient to prevent stalling of the members when the joints are closed, means for passing welding current through said joints after the joints have been closed whereby the links will be softened and said members will resume relative motion, and adjustable vmeans automatically compensating for said variations in said links for interrupting said welding current upon a predetermined amount of relative movement of said thrust members after such resumption of movement.

16. An electric resistance welding machine for closing and welding the joint of a chain link,

said machine comprising a pair of opposed thrust members relatively movable to compress the link therebetween in suchdirection as to close said joint, means for applying pressure to the -thrust members suilcient to close said joint while the link is cold but insuillcient to prevent stalling of the members when the joint is closed, means for automatically reducing said pressure to a lower constant value after the joint has been closed, and means for passing a welding current through saidjoint after the joint has been closed whereby the link will be softened and said members will K resume relative movement under such reduced pressure, and a measuring device adapted to interrupt the current upon a predetermined relative movement of the members after such resumption of movement thereof.

17. An electric resistance welding machine for closing and welding the joint of a chain link, said machine comprising a pair of opposed thrust members relatively movable to compress the link therebetween Ain such direction as to close said joint, means for applying pressure to the thrust members suicient to close said joint while the link is cold but insu'cient to prevent stalling Yof the members when the joint is closed, means for automatically reducing said pressure toa lower constant value after the joint has been closed, means for adjusting vthe point in the relative movement of the thrust members at which the 2s said lmembers willresume relative movement.

pressure is reduced, means for passing a welding current through said l joint after the joint has been closed whereby the link will be softened and under such reduced pressure, and a measuring device adapted to interrupt the current upon a predetermined relative movement ofthe members after the Welding current has been applied.

18. An electric resistance welding machine for closing and welding the joint of a chain link, said machine comprising a pair of opposed thrust members relatively movable to compress the link therebetween in such direction as to close said joint, means for -applying pressure to the thrust members sufficient to close said joint while the link is cold but insufiicient to prevent stalling of the members when the joint is closed, means for n automa/ticallyreducing said pressure to a lower comprising an l'abutment for one end of the link,

meansadapted to move the abutment to a fixed 4weldin position, a thrust member, means adapted to mo e said thrust member against the other` A end of the link to compress the link against the abutment, a pair of electrodes, means operable in timed relation to the movement of the abutment and the thrust member to contact the electrodes with the link at opposite sides of said joint, means for applying a welding current to the electrodes after vthey have Amade contact with the` link, and means movable in timed relation to the movement of the thrust member to advance the electrode adjacent thereto with the thrust member.

20. An Velectric resistance welding machine for welding the joint of a chain link, said machine comprising relatively movable members for closing the joint of a link in welding position. lmeans operating under high power to move said members relatively toward each other to close the joint of said link and operable under lower power after said. joint has been closed, means for applying a welding current across the joint after said f jointfhas been closed, and means Afor removing f said welding current after a predetermined distance `of relative travel of said members under lower power due to the contraction of the link after it has been softened.'

21. electric resistance welding machine forV welding the joints of links of variable gap, said machine comprising relatively movable members for closing the variable gaps in successive links, means operating under high power for moving said members relatively toward each other to close the gaps of said links in each instance and operable under lower power after said gaps have been closed, means for applying a welding current across the joint after the gap of a link has been closed, and means -for removing said welding current after a predetermined distance of relative travel of said members as they follow the-contraction of the link after it has been softened.

22. An electric resistance welding machine for welding the open joint of a chain link, said ma chine comprising a thrust member adapted t engage the link at one side of the joint, hy-

draulic means comprising a cylinder and piston means operable therein to move said thrust member to engage said link and. close said joint, and means operable in timed relation to the closing of said joint foi. decreasing the pressure of said piston means on said thrust member and maintaining the pressure on said link at a 4constant value during the link softening and welding operation.

23. An electric resistance welding machine for welding the open joint of a chain link, said ma chine comprising a thrust member adapted to engage a link at one side of the joint, hydraulic means comprising a cylinder and piston meansA operable therein to move vsaid member to engage said link and close said joint; means voperable to decreasethe pressure of said piston means and maintain the pressure on said link thereafter at a constant value, and means for controlling said pressure decreasing means to become effective after said link has softened and has been contracted by said thrust member. l

24. In a' welding machine of the character described the combination of an abutment member,mounted for longitudinal movement on the bed of the machine, means for moving said abutment member into position to`engage alink in weldingposition, a pair of electrodes for engagement with the sides of the link on the same side of the gap of the link as the abutment member, means for pivotally supporting said electrodes on the bed of the machine, and means for engaging said electrodes with the sides of the link after said abutment member has been moved into er1- gagement with said link.

25. In a machine of the class described the' com ination ofa longitudinally movable thrust me ber, means carried by the bed of the machine Yfor supporting and moving said thrust member into engagement with a link in welding position to close the gap in said link, a pair of electrodes adapted to cooperate with the sides of the link on the side of the gap adjacent said thrust member, means for pivotally supporting said electrodes, means for slidably supporting said pivot means on the bed of the machine, means for moving said electrodes into engagement with the sides of said link, means for applying a welding current, and means for advancing said electrodes with the thrust member as said thrust member'.A moves forward due to softening of the link by the welding current. l

26. In a machine of the character described,

the combination of a thrust member movable to close the gap in a link in welding position and to contract said link after said link has been softened, a pressure cylinder, a 'piston 1n said 5 cylinder operatively associated with said thrust member, a source of constant iluid pressure for said cylinder, means for reducing the pressure on said thrust member when the link has been closed, and means for maintaining the pressure on said i thrust member constant during a welding operation.`

27. In a resistance welding machine the combination of a thrust member adaptedto engage and close the gap in a link to be Welded and to contract the joint during a welding operation, hydraulic meansvadapted to exert a sufllcient predetermined pressure on said thrust member to cause said thrust member to close gaps of dilerentwidths at the `joints of successive links,

20 but insufficient to prevent it from stalling after said gaps have been closed, and adapted to resume its operation -under lower pressure after said link has been softened during a Welding operatori, means for applyng a Welding current 25 across said jointafter the joint has been closed, and means for interrupting the welding current after a predetermined amount of movement of said thrust member during such resumed operation.

30 28. In a Welding machine, the combination of a movable thrust member for closing the joint in a link to be welded and for compressing the link during the welding operation, means for exerting any desired initial high pressure'on said thrust 35 member to close the joint in the link and to compress the link any desired amount for any desired part of the welding operation, and means for then reducing said pressure to a desired value and maintaining suchpressure constantduring 4f, the remainder of the welding operation.

29 In a Welding machine, the combination of a movable thrustmember for closing the joint in a link to be welded and for compressing the link during the welding operation, means for exerting any desired initial high pressure on said thrust member to close the joint in said link and to compress the link during at least a part of the welding operation, means for reducing said pres- 5 sure to a desired value at any desired stage during the welding operation, means for applying a welding current across the joint of said link,

and means for interrupting said welding current after any desired amount of compression of the link has been effected during the welding operation. 30. In a welding machine, the combination of a movable thrust member for closing the joint in a link and for compressing the link during a welding operation, electrodes engageable withl the ends of said link near the joint, and means for moving said electrodes with the link ends as the link is compressed by said thrust member during the Welding operation.`

3l. In a welding machine, the combination of a movable thrust member operableto close the joint in a link, and to compress the link during a welding operation, means for applying a welding current across the joint of the link after. said joint has been closed, and adjustable means automatically compensating for variations in the size of links, for interrupting said welding current after a predetermined definite amount of compression of the link during the link softening and welding operation.

32. In a welding machine, the combination of a movable thrust member operable to close the gap in a link and to compress the link daring a welding operation, means for applying a Welding current across the ends of the link after the gap has been closed, and adjustable means compensating for variations in the length of gaps 'in links, for interrupting said welding current after a predetermined definite amount of com- 40 pression of said link during the link softening and welding operation.

' HOWARD A. DELANO. 

